Duct boot seal

ABSTRACT

A duct boot seal and a method of installing the duct boot seal in a duct boot are disclosed. The duct boot seal has a unitary body that extends through the inside of a duct boot, thereby reducing air leakage at the duct boot and its associated interfaces.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/465,202, filed Mar. 1, 2017, the entire content of which is incorporated by reference herein.

FIELD

The general inventive concepts relate to HVAC systems and, more particularly, to a device for reducing air leaks at a duct boot in an HVAC system, as well as a method of installing the device.

BACKGROUND

As known in the art, ducts and conduits are used to convey air in building heating, ventilation, and air conditioning (HVAC) systems. The ducts in a residential building or home can be arranged in many different configurations, such as a trunk and branch configuration. A portion of a trunk and branch configuration is shown in FIG. 1. A plenum 102 or trunk conveys air from an air handler 104 of an HVAC system 100 through various ducts and distribution boxes to smaller branch ducts that carry the air to individual rooms of the home.

Many ducts, particularly trunk ducts 106 and plenums 102, are formed of sheet metal and are rigid. Branch ducts 108 may be rigid sheet metal ducts or flexible ducts. Flexible ducts are typically formed of a wire-reinforced core, an insulation layer, and an outer sheath. The branch ducts 108 may terminate at duct boots 110 that connect the branch ducts 108 to air registers arranged in the walls, floor, or ceiling of a room.

A conventional duct boot 200 is shown in FIGS. 2A-2D. The duct boot 200 includes a rigid body 202 having a circular opening 204 on one side of the body 202 and a rectangular opening 206 on another side of the body 202. A central axis of the circular opening 204 can be offset from a central axis of the rectangular opening 206, such as by 90 degrees.

The circular opening 204 is defined by a connecting collar 208 that allows the duct boot 200 to be joined to a branch duct (e.g., the branch duct 108). In this manner, the circular opening 204 defines an inlet port for the duct boot 200.

The rectangular opening 206 is designed to be aligned with a similar opening in a wall, floor, or ceiling. In this manner, the rectangular opening 206 defines an outlet port for the duct boot 200. A gap between the rectangular opening 206 and the wall opening allows a register to be placed in the wall opening and cover the rectangular opening 206. Often, the register can be used to meter the flow of air exiting the duct boot 200.

The duct boot 200 is made of multi-piece sheet metal construction. This multi-piece construction presents a source of air leakage from the duct boot 200 along its seams 220 (see FIG. 2C).

The interface between the branch duct 108 and the duct boot 200 is also a potential source of air leakage that can contribute to energy loss from the HVAC system 100 because it provides a pathway for conditioned air to leak into an unconditioned space, rather than being conveyed to the conditioned room. Existing methods of connecting the branch duct 108 to the duct boot 200 include sheet metal screws, mastic, adhesive tape, and plastic ties. These methods may be used on their own or in concert. Mastic is a non-hardening adhesive compound that may be used on its own or with a reinforcing material such as fiberglass mesh tape. These methods may be ineffective, expensive, difficult to implement, time consuming, messy, etc.

Likewise, the interface between the duct boot 200 and a room opening (e.g., an opening in a wall, floor, ceiling, or the like) is another potential source of air leakage that can contribute to energy loss from the HVAC system 100 because it provides a pathway for conditioned air to leak into an unconditioned space, rather than being conveyed to the conditioned room. While the duct boot 200 itself is often sealed (e.g., with mastic) to cover the aforementioned seams, sealing the duct boot to the opening needs to be done after installation of the wall/floor/ceiling material and, thus, can be overlooked as different installers are often involved. When the duct boot 200 is sealed to the opening, it is typically done so using caulk. The quality and consistency of such a seal depends on the installer.

In view of the above, there is an unmet need for a device, and an associated method of installing the device, for forming a more consistent seal from the branch duct, through the duct boot, and past the opening, thereby reducing air leakage at the duct boot and its associated interfaces.

SUMMARY

The general inventive concepts relate to and contemplate duct boot seals, as well as methods of installing the duct boot seals and systems incorporating the duct boot seals. Accordingly, the general inventive concepts encompass methods of and systems for preventing air leakage at a duct boot, wherein a continuous duct boot seal extends through the duct boot (e.g., from a branch duct connection to an opening for receiving a register).

According to an exemplary embodiment, a duct boot seal is provided. The duct boot seal comprises an airtight body including one or more side walls extending from an upper wall; wherein the one or more side walls define a first opening on a first side of the body; wherein the body includes a raised portion defining a second opening on a second side of the body; wherein the body includes a peripheral flange that surrounds the first opening; and wherein a gasket is disposed on at least one side of the peripheral flange. In some exemplary embodiments, a gasket is disposed on both sides of the peripheral flange.

In some exemplary embodiments, the body includes four side walls; and the first opening is rectangular. In some exemplary embodiments, the body includes four side walls; and the first opening is square. In some exemplary embodiments, the first opening has a width in the range of 2-24 inches; and the first opening has a length in the range of 6-24 inches.

In some exemplary embodiments, the second opening is circular. In some exemplary embodiments, a diameter of the second opening is in the range of 4-22 inches.

In some exemplary embodiments, a length of the raised portion is in the range of 2-4 inches. In some exemplary embodiments, a length of the raised portion is in the range of 4-8 inches.

In some exemplary embodiments, the second side of the body is the upper wall.

In some exemplary embodiments, the body defines a non-rectangular volume therein.

In some exemplary embodiments, each of the side walls includes a plurality of folds, creases, or the like that allow a length of the side wall to vary.

In some exemplary embodiments, the body is flexible.

In some exemplary embodiments, the duct boot seal further comprises at least one baffle.

According to an exemplary embodiment, a method of installing a duct boot seal in a duct boot situated adjacent to an opening in a structure is provided. The method comprises inserting the duct boot seal through the opening in the structure such that an airtight body of the duct boot seal extends through the opening in the structure and into the duct boot, while a flanged portion of the body does not pass through the opening.

In some exemplary embodiments, the structure is one of a wall, floor, and ceiling.

In some exemplary embodiments, the method further comprises positioning a raised portion of the body of the duct boot seal at least partly inside a collar of the duct boot, the collar operable to connect the duct boot to a branch duct.

In some exemplary embodiments, the raised portion is at least partially affixed to an inner surface of the collar by an adhesive.

In some exemplary embodiments, the raised portion is at least partially affixed to an inner surface of the collar by an annular member friction fit inside the collar.

In some exemplary embodiments, the method further comprises extending a raised portion of the body of the duct boot seal through a collar of the duct boot, the collar operable to connect the duct boot to a branch duct, and folding the raised portion around at least a portion of an outer surface of the collar.

In some exemplary embodiments, the flanged portion includes a gasket.

In some exemplary embodiments, the method further comprises affixing the flanged portion of the body to the structure.

Numerous other aspects, advantages, and/or features of the general inventive concepts will become more readily apparent from the following detailed description of exemplary embodiments, from the claims, and from the accompanying drawings being submitted herewith.

BRIEF DESCRIPTION OF THE DRAWINGS

The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:

FIG. 1 is a diagram of a conventional HVAC system with ducts arranged in a trunk and branch configuration.

FIGS. 2A-2D show one type of conventional duct boot. FIG. 2A is a perspective view of the duct boot. FIG. 2B is a front elevational view of the duct boot. FIG. 2C is a cross sectional view of the duct boot, along line C-C in FIG. 2B. FIG. 2D is a top plan view of the duct boot.

FIGS. 3A-3D show a duct boot seal, according to an exemplary embodiment. FIG. 3A is a perspective view of the duct boot seal. FIG. 3B is a side elevational view of the duct boot seal. FIG. 3C is a bottom plan view of the duct boot seal. FIG. 3D is another perspective view of the duct boot seal, illustrating its non-rigid construction.

FIG. 4 is a diagram of an installation of the duct boot seal of FIGS. 3A-3D into a duct boot, according to an exemplary embodiment.

FIG. 5 is a diagram of an installation of the duct boot seal of FIGS. 3A-3D into a duct boot, according to an exemplary embodiment.

FIG. 6 shows an annular member, according to an exemplary embodiment, for use in the installation of FIG. 5.

FIG. 7 shows an annular member, according to an exemplary embodiment, for use in the installation of FIG. 5.

FIG. 8 is a diagram of an installation of the duct boot seal of FIGS. 3A-3D into a duct boot, according to an exemplary embodiment.

FIGS. 9A-9B show a duct boot seal, according to an exemplary embodiment. FIG. 9A is a side elevational view of the duct boot seal. FIG. 9B is a bottom plan view of the duct boot seal.

FIG. 10 is a diagram of an installation of the duct boot seal of FIGS. 9A-9B into a duct boot, according to an exemplary embodiment.

FIGS. 11A-11C show a duct boot seal, according to an exemplary embodiment. FIG. 11A is a perspective view of the duct boot seal. FIG. 11B is a side elevational view of the duct boot seal. FIG. 11C is a bottom plan view of the duct boot seal.

FIG. 12 is a diagram of an installation of the duct boot seal of FIGS. 11A-11C into a duct boot, according to an exemplary embodiment.

DETAILED DESCRIPTION

While the general inventive concepts are susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the general inventive concepts. Accordingly, the general inventive concepts are not intended to be limited to the specific embodiments illustrated herein.

The general inventive concepts encompass methods of and systems for preventing air leakage at a duct boot, wherein a continuous duct boot seal extends through the duct boot.

A duct boot seal 300, according to an exemplary embodiment, is shown in FIGS. 3A-3D. The duct boot seal 300 includes a hollow body 302 formed from one or more side walls 304 that extend below or otherwise from an upper wall 306. In some embodiments, the side walls 304 are substantially perpendicular to the upper wall 306 when the duct boot seal 300 is installed (see FIG. 4). The side walls 304 define a lower opening 308 of the body 302. In some embodiments, the lower opening 308 is rectangular with a width in the range of 2-24 inches and a length in the range of 6-24 inches.

A flange 310 extends from the side walls 304 around a periphery of the lower opening 308. In some embodiments, the flange 310 is substantially perpendicular to the side walls 304 when the duct boot seal 300 is installed. The flange 310 supports a gasket 312 on at least one of its surface (e.g., its lower surface). In some embodiments, the flange 310 has a gasket 312 on both surfaces (i.e., its upper surface and its lower surface). The gasket 312 extends around the entire flange 310 so as to frame the lower opening 308. In some embodiments, the gasket 312 itself forms the flange 310.

The body 302 also includes a raised portion 314 that extends above the upper wall 306. An end of the raised portion 314 defines an upper opening 316 of the body 302. In some embodiments, the body 302 below the raised portion 314 forms a rectangular volume (see FIG. 4). In some embodiments, the body 302 below the raised portion 314 could form a non-rectangular volume (see FIG. 10). In some embodiments, the raised portion 314 is circular with a diameter in the range of 4-22 inches. In some embodiments, a fully extended length of the raised portion 314 is in the range of 2-4 inches.

The hollow body 302, including the flange 310 and the raised portion 314, are preferably, but not necessarily, formed as a one-piece structure. In some embodiments, the hollow body 302, including the flange 310 and the raised portion 314, are formed from two or more pieces of material that are joined (e.g., heat bonded) to one another to create a unitary structure. In this latter instance, a thickness of the material may not be the same throughout the unitary structure. For example, regions where two pieces were joined together may be thicker than other regions of the unitary structure.

The hollow body 302, including the flange 310 and the raised portion 314, are formed from any suitable air impermeable material. For example, the body 302 can be made from a material having one or more desirable properties. By way of example, and not by way of limitation, such properties might include mold resistance, fire resistance, odor resistance, durability, acoustical properties, etc.

Preferably, but not necessarily, the air impermeable material is flexible (see FIG. 3D). This flexibility facilitates installation of the duct boot seal 300 within the duct boot. In some embodiments, an uncompressed profile of the duct boot seal (e.g., the duct boot seal 300) substantially conforms to the inner dimensions of the duct boot (see FIG. 4). In some embodiments, the uncompressed profile of the duct boot seal (e.g., the duct boot seal 900) is smaller than the inner dimensions of the duct boot, which facilitates its use in other duct boots having different inner dimensions.

In this manner, the duct boot seal 300 forms a continuous channel through the duct boot (e.g., from the upper opening 316 to the lower opening 308), wherein leakage of the air flowing through the channel is prevented. In this embodiment, the upper opening 316 and the lower opening 308 are aligned (e.g., coaxial) with one another.

Furthermore, the flange 310 of the duct boot seal 300 extends beyond the duct boot and through an opening in a room (e.g., in a wall, floor, or ceiling of the room). In some embodiments, the flange 310 can be affixed, such as by an adhesive or a mechanical attachment (e.g., staple) to a surface of the wall, floor, or ceiling in the room. In some embodiments, the flange 310 is not affixed to the surface of the wall, floor, or ceiling in the room. Regardless, the gasket 312 on the flange 310 is compressed between the surface of the wall, floor, or ceiling in the room and a register that is inserted within the opening. Thus, the gasket 312 prevents air flowing through the duct boot seal from leaking through any gap between the opening and the duct boot.

An installation 400 of the duct boot seal 300 in a duct boot 402, according to an exemplary embodiment, is shown in FIG. 4.

The installation 400 includes the duct boot 402 situated adjacent to an opening in a wall (i.e., drywall 440) of a room. The duct boot 402 has a circular opening 404 on one end and a rectangular opening 406 on another end. For purposes of illustrating various aspects of the general inventive concepts, the circular opening 404 and the rectangular opening 406 are shown aligned in FIG. 4. However, the general inventive concepts are applicable even if the circular opening 404 and the rectangular opening 406 are not aligned (i.e., are offset from one another).

The circular opening 404 is defined by a connecting collar 408 that allows the duct boot 402 to be joined to a branch duct (e.g., the branch duct 108). The branch duct may be a rigid (e.g., metal) duct or a flexible duct.

The rectangular opening 406 is positioned adjacent to and in general alignment with the opening made in the drywall 440. The opening in the drywall 440 is typically rectangular in shape and sized to receive a corresponding air register (not shown) positioned therein. In some embodiments, a portion of the duct boot 402 extends at least partially through the opening in the drywall 440.

In the installation 400, the duct boot seal 300 is inserted into the duct boot 402, for example, through the opening in the drywall 440. Because the duct boot seal 300 has a flexible or otherwise conforming construction, it can be readily manipulated into position within the duct boot 402.

Once positioned within the duct boot 402, the side walls 304 of the duct boot seal 300 are generally parallel to the side walls 410 of the duct boot 402. Likewise, an upper wall 306 of the duct boot seal 300 is generally parallel to an upper wall 412 of the duct boot 402.

In some embodiments, one or more of the side walls 304 of the duct boot seal 300 are at least partially attached to or otherwise interfaced with one or more corresponding sidewalls 410 of the duct boot 402. The side walls 304, 410 may be attached to one another in any suitable matter, for example, via an adhesive. In some embodiments, the side walls 304 of the duct boot seal 300 are not attached to or otherwise interfaced with one or more corresponding sidewalls 410 of the duct boot 402.

In some embodiments, the upper wall 306 of the duct boot seal 300 is at least partially attached to or otherwise interfaced with the upper wall 412 of the duct boot 402. The upper walls 306, 412 may be attached to one another in any suitable matter, for example, via an adhesive. In some embodiments, the upper wall 306 of the duct boot seal 300 is not attached to or otherwise interfaced with the upper wall 412 of the duct boot 402.

In the installation 400, the raised portion 314 of the duct boot seal 300 is situated inside the connecting collar 408 of the duct boot 402. In some embodiments, the raised portion 314 of the duct boot seal 300 is at least partially attached to or otherwise interfaced with an inner surface of the connecting collar 408 of the duct boot 402. For example, an adhesive could be used to connect the raised portion 314 to the inner surface of the connecting collar 408. As another example, a mechanical attachment or device (e.g., magnets) could be used to connect the raised portion 314 to the inner surface of the connecting collar 408.

In some embodiments, an annular member 502 is used to connect the raised portion 314 of the duct boot seal 300 to the inner surface of the connecting collar 408 of the duct boot 402, as shown in the installation 500 of FIG. 5. In one exemplary embodiment, the annular member 502 is a flexible ring 600 as shown in FIG. 6. The ring 600 is made of an elastomeric or similar material. An outer diameter of the ring 600 is slightly larger than an inner diameter of the connecting collar 408. Accordingly, the ring 600 can be forced (i.e., friction fit) within the connecting collar 408 to firmly press and hold the raised portion 314 of the duct boot seal 300 against the inner surface of the connecting collar 408 of the duct boot 402. In another exemplary embodiment, the annular member 502 is a rigid or semi-rigid ring 700 as shown in FIG. 7. The ring 700 is made of a rigid or semi-rigid material. An outer diameter of the ring 700 is slightly smaller than an inner diameter of the connecting collar 408. Accordingly, the ring 700 can be readily fit within the connecting collar 408. To “lock” the ring 700 within the connecting collar 408, a wedge member 702 can be inserted into a grooved gap 704 in the ring 700, so as to increase its outer diameter. With the wedge member 702 in place, the ring 700 firmly presses and holds the raised portion 314 of the duct boot seal 300 against the inner surface of the connecting collar 408 of the duct boot 402.

With the raised portion 314 of the duct boot seal 300 attached to the duct boot 402 inside the connecting collar 408 of the duct boot 402, the installation 400 is further completed by having the peripheral flange 310 of the duct boot seal 300 remain outside or otherwise extend through the opening in the drywall 440. In particular, the flange 310 is sufficiently wide to cover a gap between the rectangular opening in the drywall 440 and the rectangular opening 406 of the duct boot 402. In some exemplary embodiments, a width of the flange 310 is in the range of ½-1½ inches. The flange 310 of the duct boot seal 300 is disposed in the conditioned room and will typically abut the drywall 440 surrounding the opening in the drywall 440. In some embodiments, the flange 310 is at least partially connected to the drywall 440, for example, by an adhesive. In some embodiments, the flange 310 is not connected to the drywall 440. In either case, the gasket 312 portion of the flange 310 frames the opening in the drywall 440. When an air register (not shown) is situated in the opening of the drywall 440, the air register will compress or otherwise interface with the gasket 312 of the duct boot seal 300 to prevent leakage of air being delivered by the duct boot 402 prior to the air flowing out of the register.

As shown in the installation 400, once the duct boot seal 300 is installed in the duct boot 402, the upper opening 316 of the duct boot seal 300 is generally coaxial with the circular opening 404 of the duct boot 402, i.e., relative to the axis z. Likewise, the lower opening 308 of the duct boot seal 300 is generally coaxial with the rectangular opening 406 of the duct boot 402, with respect to the z-axis. In this manner, an air-tight channel is formed through the duct boot 402 and out past the drywall 440, thereby preventing air leakages at the duct boot 402 or the interface between the duct boot 402 and the drywall 440.

An installation 800 of the duct boot seal 300 in the duct boot 402, according to another exemplary embodiment, is shown in FIG. 8. In the installation 800, the duct boot seal 300 includes a longer raised portion 802, as compared to the raised portion 314 of the duct boot seal 300 in the installation 400. For example, the raised portion 802 can have a fully extended length within the range of 4-8 inches. The installation 800 is otherwise identical to the installation 400, except for the manner in which the raised portion 802 interfaces with the connecting collar 408 of the duct boot 402. In particular, as shown in FIG. 8, the raised portion 802 of the duct boot seal 300 extends entirely through the connecting collar 408 of the duct boot 402. Thereafter, an excess portion of the raised portion 802 is folded down on and around the connecting collar 408. When a branch duct of an HVAC system is connected to or otherwise interfaced with the connecting collar 408 of the duct boot 402, the branch duct will surround at least some of the raised portion 802 situated around an outer surface of the connecting collar 408. Thus, by securing the branch duct to the connecting collar 408 (e.g., using tape, zip ties, etc.), the raised portion 802 becomes entrapped between the branch duct and the connecting collar 408, thereby forming a continuous seal that extends from outside the connecting collar 408 and into and through the inside of the duct boot 402. This represents an improved seal at the branch duct-to-duct boot interface.

A duct boot seal 900, according to an exemplary embodiment, is shown in FIGS. 9A-9B. The duct boot seal 900 includes a hollow body 902 formed from one or more side walls 904 that extend below or otherwise from an upper wall 906. In some embodiments, the side walls 904 include folds 930, creases, or the like that create an accordion-like portion, as shown in detail c of FIG. 9A. Accordingly, a length of the side walls 904 (and, thus, an overall height of the duct boot seal 900) can be varied. In this manner, the uncompressed profile of the duct boot seal 900 is variable, which facilitates its use in other duct boots having different depths.

The side walls 904 form an angle θ₁ relative to the upper wall 906 when the duct boot seal 900 is installed (see FIG. 10). In general, θ₁ is greater than 90 degrees. The side walls 904 define a lower opening 908 of the body 902. In some embodiments, the lower opening 908 is rectangular with a width in the range of 2-24 inches and a length in the range of 6-24 inches.

A flange 910 extends from the side walls 904 around a periphery of the lower opening 908. The side walls 904 form an angle θ₂ relative to the flange 910 when the duct boot seal 900 is in a fully uncompressed state (see FIG. 9A). In general, θ₂ is greater than 90 degrees. The flange 910 supports a gasket 912 on its lower surface. The gasket 912 extends around the entire flange 910 so as to frame the lower opening 908. In some embodiments, the gasket 912 itself forms the flange 910.

The body 902 also includes a raised portion 914 that extends above the upper wall 906. In some embodiments, the raised portion 914 is circular with a diameter in the range of 4-22 inches. In some embodiments, the raised portion 914 has a fully extended length intended to terminate within the connecting collar of the duct boot, such as a length in the range of 2-4 inches. In some other embodiments, the raised portion 914 has a fully extended length intended to terminate outside the connecting collar of the duct boot, such as a length in the range of 4-8 inches.

The hollow body 902, including the flange 910 and the raised portion 914, is a unitary structure formed from any suitable air impermeable material. For example, the body 902 can be made from. Preferably, but not necessarily, the air impermeable material is flexible. This flexibility facilitates installation of the duct boot seal 900 within the duct boot. As shown in FIG. 10, the uncompressed profile of the duct boot seal 900 is smaller than the inner dimensions of the duct boot, which facilitates its use in other duct boots having different inner dimensions.

An installation 1000 of the duct boot seal 900 in a duct boot 402, according to an exemplary embodiment, is shown in FIG. 10.

The installation 1000 includes the duct boot 402 situated adjacent to an opening in a wall (i.e., drywall 440) of a room. The duct boot 402 has a circular opening 404 on one end and a rectangular opening 406 on another end. For purposes of illustrating various aspects of the general inventive concepts, the circular opening 404 and the rectangular opening 406 are shown aligned in FIG. 10. However, the general inventive concepts are applicable even if the circular opening 404 and the rectangular opening 406 are not aligned (i.e., are offset from one another).

The circular opening 404 is defined by a connecting collar 408 that allows the duct boot 402 to be joined to a branch duct (e.g., the branch duct 108). The branch duct may be a rigid (e.g., metal) duct or a flexible duct.

The rectangular opening 406 is positioned adjacent to and in general alignment with the opening made in the drywall 440. The opening in the drywall 440 is typically rectangular in shape and sized to receive a corresponding air register (not shown) positioned therein. In some embodiments, a portion of the duct boot 402 extends at least partially through the opening in the drywall 440.

In the installation 1000, the duct boot seal 900 is inserted into the duct boot 402, for example, through the opening in the drywall 440. Because the duct boot seal 900 has a flexible construction, it can be readily manipulated into position within the duct boot 402.

Once positioned within the duct boot 402, the side walls 904 of the duct boot seal 900 are spaced apart from the side walls 410 of the duct boot 402. As shown in FIG. 10, the side walls 904 slope inward from the rectangular opening 406 of the duct boot 402 to the circular opening 404 of the duct boot 402. An upper wall 906 of the duct boot seal 900 is generally parallel to an upper wall 412 of the duct boot 402.

In some embodiments, the upper wall 906 of the duct boot seal 900 is at least partially attached to or otherwise interfaced with the upper wall 412 of the duct boot 402. The upper walls 906, 412 may be attached to one another in any suitable matter, for example, via an adhesive. In some embodiments, the upper wall 906 of the duct boot seal 900 is not attached to or otherwise interfaced with the upper wall 412 of the duct boot 402.

In the installation 1000, the raised portion 914 of the duct boot seal 900 is situated inside the connecting collar 408 of the duct boot 402. In some embodiments, the raised portion 914 of the duct boot seal 900 is at least partially attached to or otherwise interfaced with an inner surface of the connecting collar 408 of the duct boot 402. For example, an adhesive could be used to connect the raised portion 914 to the inner surface of the connecting collar 408. As another example, a mechanical attachment or device (e.g., magnets) could be used to connect the raised portion 914 to the inner surface of the connecting collar 408.

One of ordinary skill in the art will appreciate that an annular member, such as the annular member 502 shown in the installation 500 of FIG. 5, could also be used in the installation 1000. Likewise, one of ordinary skill in the art will appreciate that the duct boot seal 900 could include a longer raised portion, such as the raised portion 802 shown in the installation 800 of FIG. 8.

In some embodiments, the duct boot seal 900 includes one or more baffles 920. The baffles 920 can be any structure that reduces movement of the duct boot seal 900 (in particular, the side walls 904 of the duct boot seal 900) during the flow of air through the duct boot seal 900. For example, the baffle 920 could be a weight attached to the duct boot seal 900. As another example, a thickness of the sidewalls 904 of the duct boot seal 900 could be varied to function as a baffle. By reducing movement of the duct boot seal 900 during use thereof, the baffles 920 can prevent or otherwise reduce any undesired noise resulting therefrom.

With the raised portion 914 of the duct boot seal 900 attached to the duct boot 402 inside the connecting collar 408 of the duct boot 402, the installation 1000 is further completed by having the peripheral flange 910 of the duct boot seal 900 remain outside or otherwise extend through the opening in the drywall 440. In particular, the flange 910 is sufficiently wide to cover a gap between the rectangular opening in the drywall 440 and the rectangular opening 406 of the duct boot 402. In some exemplary embodiments, a width of the flange 910 is in the range of ½-1½ inches.

The flange 910 of the duct boot seal 900 is disposed in the conditioned room and will typically abut the drywall 440 surrounding the opening in the drywall 440. In some embodiments, the flange 910 is at least partially connected to the drywall 440, for example, by an adhesive. In some embodiments, the flange 910 is not connected to the drywall 440. In either case, the gasket 912 portion of the flange 910 frames the opening in the drywall 440. When an air register (not shown) is situated in the opening of the drywall 440, the air register will compress or otherwise interface with the gasket 912 of the duct boot seal 900 to prevent leakage of air being delivered by the duct boot 402 prior to the air flowing out of the register.

As shown in the installation 1000, once the duct boot seal 900 is installed in the duct boot 402, the upper opening 916 of the duct boot seal 900 is generally coaxial with the circular opening 404 of the duct boot 402, i.e., relative to the axis z. Likewise, the lower opening 908 of the duct boot seal 900 is generally coaxial with the rectangular opening 406 of the duct boot 402, with respect to the z-axis. In this manner, an air-tight channel is formed through the duct boot 402 and out past the drywall 440, thereby preventing air leakages at the duct boot 402 or the interface between the duct boot 402 and the drywall 440.

A duct boot seal 1100, according to an exemplary embodiment, is shown in FIGS. 11A-11C. The duct boot seal 1100 includes a hollow body 1102 formed from one or more side walls 1104 that extend below or otherwise from an upper wall 1106. In some embodiments, the side walls 1104 are substantially perpendicular to the upper wall 1106 when the duct boot seal 1100 is installed (see FIG. 12). The side walls 1104 define a lower opening 1108 of the body 1102. In some embodiments, the lower opening 1108 is rectangular with a width in the range of 2-24 inches and a length in the range of 6-24 inches.

A flange 1110 extends from the side walls 1104 around a periphery of the lower opening 1108. In some embodiments, the flange 1110 is substantially perpendicular to the side walls 1104 when the duct boot seal 1100 is installed. The flange 1110 supports a gasket 1112 on at least one of its surface (e.g., its lower surface). In some embodiments, the flange 1110 has a gasket 1112 on both surfaces (i.e., its upper surface and its lower surface). The gasket 1112 extends around the entire flange 1110 so as to frame the lower opening 1108. In some embodiments, the gasket 1112 itself forms the flange 1110.

The body 1102 also includes a projecting portion 1114 that extends out of one of the side walls 1104 situated below the upper wall 1106. An end of the projecting portion 1114 defines a side opening 1116 of the body 1102. In some embodiments, the body 1102 below the upper wall 1106 forms a rectangular volume. In some embodiments, the body 1102 below the upper wall 1106 could form a non-rectangular volume. In some embodiments, the projecting portion 1114 is circular with a diameter in the range of 4-22 inches. In some embodiments, a fully extended length of the projecting portion 1114 is in the range of 2-4 inches.

The hollow body 1102, including the flange 1110 and the projecting portion 1114, are preferably, but not necessarily, formed as a one-piece structure. In some embodiments, the hollow body 1102, including the flange 1110 and the projecting portion 1114, are formed from two or more pieces of material that are joined (e.g., heat bonded) to one another to create a unitary structure. In this latter instance, a thickness of the material may not be the same throughout the unitary structure. For example, regions where two pieces were joined together may be thicker than other regions of the unitary structure.

The hollow body 1102, including the flange 1110 and the projecting portion 1114, are formed from any suitable air impermeable material. For example, the body 1102 can be made from a material having one or more desirable properties. By way of example, and not by way of limitation, such properties might include mold resistance, fire resistance, odor resistance, durability, acoustical properties, etc.

Preferably, but not necessarily, the air impermeable material is flexible. This flexibility facilitates installation of the duct boot seal 1100 within the duct boot. In some embodiments, an uncompressed profile of the duct boot seal substantially conforms to the inner dimensions of the duct boot. In some embodiments, the uncompressed profile of the duct boot seal is smaller than the inner dimensions of the duct boot, which facilitates its use in other duct boots having different inner dimensions.

In this manner, the duct boot seal 1100 forms a continuous channel through the duct boot (e.g., from the side opening 1116 to the lower opening 1108), wherein leakage of the air flowing through the channel is prevented. In some embodiments, the side opening 1116 and the lower opening 1108 are offset from (e.g., not aligned with) one another. For example, in this embodiment, the side opening 1116 is offset 90 degrees from the lower opening 1108.

Furthermore, the flange 1110 of the duct boot seal 1100 extends beyond the duct boot and through an opening in a room (e.g., in a wall, floor, or ceiling of the room). In some embodiments, the flange 1110 can be affixed, such as by an adhesive or a mechanical attachment (e.g., staple) to a surface of the wall, floor, or ceiling in the room. In some embodiments, the flange 1110 is not affixed to the surface of the wall, floor, or ceiling in the room. Regardless, the gasket 1112 on the flange 1110 is compressed between the surface of the wall, floor, or ceiling in the room and a register that is inserted within the opening. Thus, the gasket 1112 prevents air flowing through the duct boot seal from leaking through any gap between the opening and the duct boot.

An installation 1200 of the duct boot seal 1100 in a duct boot 1202, according to an exemplary embodiment, is shown in FIG. 12.

The installation 1200 includes the duct boot 1202 situated adjacent to an opening in a wall (i.e., drywall 1240) of a room. The duct boot 1202 has a circular opening 1204 on one end and a rectangular opening 1206 on another end. For purposes of illustrating various aspects of the general inventive concepts, the circular opening 1204 and the rectangular opening 1206 are shown offset from one another in FIG. 12. However, the general inventive concepts are applicable even if the circular opening 1204 and the rectangular opening 1206 are aligned with one another (see FIG. 4).

The circular opening 1204 is defined by a connecting collar 1208 that allows the duct boot 1202 to be joined to a branch duct (e.g., the branch duct 108). The branch duct may be a rigid (e.g., metal) duct or a flexible duct.

The rectangular opening 1206 is positioned adjacent to and in general alignment with the opening made in the drywall 1240. The opening in the drywall 1240 is typically rectangular in shape and sized to receive a corresponding air register (not shown) positioned therein. In some embodiments, a portion of the duct boot 1202 extends at least partially through the opening in the drywall 1240.

In the installation 1200, the duct boot seal 1100 is inserted into the duct boot 1202, for example, through the opening in the drywall 1240. Because the duct boot seal 1100 has a flexible or otherwise conforming construction, it can be readily manipulated into position within the duct boot 1202.

Once positioned within the duct boot 1202, the side walls 1104 of the duct boot seal 1100 are generally parallel to the side walls 1210 of the duct boot 1202. Likewise, an upper wall 1106 of the duct boot seal 1100 is generally parallel to an upper wall 1212 of the duct boot 402. Notwithstanding this (or any other disclosed) exemplary embodiment, the general inventive concepts contemplate duct boot seals with different designs, such those having fewer or more than four side walls and fewer or more than one upper wall, as well as those having at least some adjacent walls that meet at angles other than 90 degrees. Such duct boot seals being well suited for ducts boots (e.g., the duct boot 200 of FIG. 2A) having a more complex construction than that of the duct boot 1202.

In some embodiments, one or more of the side walls 1104 of the duct boot seal 1100 are at least partially attached to or otherwise interfaced with one or more corresponding sidewalls 1210 of the duct boot 1202. The side walls 1104, 1210 may be attached to one another in any suitable matter, for example, via an adhesive. In some embodiments, the side walls 1104 of the duct boot seal 1100 are not attached to or otherwise interfaced with one or more corresponding sidewalls 1210 of the duct boot 1202.

In some embodiments, the upper wall 1106 of the duct boot seal 1100 is at least partially attached to or otherwise interfaced with the upper wall 1212 of the duct boot 1202. The upper walls 1106, 1212 may be attached to one another in any suitable matter, for example, via an adhesive. In some embodiments, the upper wall 1106 of the duct boot seal 1100 is not attached to or otherwise interfaced with the upper wall 1212 of the duct boot 1202.

In the installation 1200, the projecting portion 1114 of the duct boot seal 1100 is situated inside the connecting collar 1208 of the duct boot 1202. In some embodiments, the projecting portion 1114 of the duct boot seal 1100 is at least partially attached to or otherwise interfaced with an inner surface of the connecting collar 1208 of the duct boot 1202. For example, an adhesive could be used to connect the projecting portion 1114 to the inner surface of the connecting collar 1208. As another example, a mechanical attachment or device (e.g., magnets) could be used to connect the projecting portion 1114 to the inner surface of the connecting collar 1208.

In some embodiments, as shown in FIG. 12, a length of the projecting portion 1114 of the duct boot seal 1100 is longer than a length of the connecting collar 1208 of the duct boot 1202, such that the projecting portion 1114 can extend beyond and be folded down over an outer surface of the connecting collar 1208, prior to the duct boot 1202 being interfaced with the branch duct.

As shown in the installation 1200, once the duct boot seal 1100 is installed in the duct boot 1202, the side opening 1116 of the duct boot seal 1100 is generally coaxial with the circular opening 1204 of the duct boot 1202, i.e., relative to the axis x. Likewise, the lower opening 1108 of the duct boot seal 1100 is generally coaxial with the rectangular opening 1206 of the duct boot 1202, with respect to the axis y. The x-axis and the y-axis are offset from one another by an angle θ. In this example, θ is equal to 90 degrees. However, the angel θ can, practically speaking, be any value. In this manner, an air-tight channel is formed through the duct boot 1202 and out past the drywall 1240, thereby preventing air leakages at the duct boot 1202 or the interface between the duct boot 1202 and the drywall 1240.

The scope of the general inventive concepts are not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the methods and systems disclosed. For example, the general inventive concepts are not limited to any particular arrangement of ductwork and corresponding duct boots. Furthermore, while various exemplary installations of the duct boot seal are provided that describe insertion of the duct boot seal into the duct boot through a structural opening, the general inventive concepts contemplate other installation techniques as well, such as interfacing the duct boot seal with the duct boot (and related branch duct) prior to forming such structural component (e.g., prior to installing drywall). It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and claimed herein, and any equivalents thereof. 

1. A duct boot seal comprising: an airtight body including one or more side walls extending from an upper wall; wherein the one or more side walls define a first opening on a first side of the body; wherein the body includes a raised portion defining a second opening on a second side of the body; wherein the body includes a peripheral flange that surrounds the first opening; and wherein a gasket is disposed on at least one side of the peripheral flange.
 2. The duct boot seal of claim 1, wherein the body includes four side walls; and wherein the first opening is rectangular.
 3. The duct boot seal of claim 2, wherein the first opening has a width in the range of 2-24 inches; and wherein the first opening has a length in the range of 6-24 inches.
 4. The duct boot seal of claim 1, wherein the second opening is circular.
 5. The duct boot seal of claim 4, wherein a diameter of the second opening is in the range of 4-22 inches.
 6. The duct boot seal of claim 1, wherein a length of the raised portion is in the range of 2-4 inches.
 7. The duct boot seal of claim 1, wherein a length of the raised portion is in the range of 4-8 inches.
 8. The duct boot seal of claim 1, wherein the second side of the body is the upper wall.
 9. The duct boot seal of claim 1, wherein the body defines a non-rectangular volume therein.
 10. The duct boot seal of claim 1, wherein a first gasket is disposed on a first side of the peripheral flange, and wherein a second gasket is disposed on a second side of the peripheral flange.
 11. The duct boot seal of claim 1, wherein at least one of the side walls has a variable length.
 12. The duct boot seal of claim 1, wherein the body is flexible.
 13. The duct boot seal of claim 1, further comprising at least one baffle.
 14. A method of installing a duct boot seal in a duct boot situated adjacent to an opening in a structure, the method comprising inserting the duct boot seal through the opening in the structure such that an airtight body of the duct boot seal extends through the opening in the structure and into the duct boot, while a flanged portion of the body does not pass through the opening.
 15. The method of claim 14, wherein the structure is one of a wall, floor, and ceiling.
 16. The method of claim 14, further comprising positioning a raised portion of the body of the duct boot seal at least partly inside a collar of the duct boot, the collar operable to connect the duct boot to a branch duct.
 17. The method of claim 16, wherein the raised portion is at least partially affixed to an inner surface of the collar by an adhesive.
 18. The method of claim 16, wherein the raised portion is at least partially affixed to an inner surface of the collar by an annular member friction fit inside the collar.
 19. The method of claim 14, further comprising extending a raised portion of the body of the duct boot seal through a collar of the duct boot, the collar operable to connect the duct boot to a branch duct, and folding the raised portion around at least a portion of an outer surface of the collar.
 20. The method of claim 14, wherein the flanged portion includes a gasket.
 21. The method of claim 14, further comprising affixing the flanged portion of the body to the structure. 